Finite element modeling of non-constrained closed die forging (Modified upsetting) using deform 3d^tm

This paper reports on the three-dimensional analysis of the upsetting process using Deform 3D simulation software. The influence of both die moving during the metal upsetting process denoted as modified upsetting process (similar to unconstrained closed die forging) was compared to conventional upsetting (when only one die moves) was investigated. From the upsetting simulation process the deformation load, stress and strain distribution results were obtained. The simulation results showed that the modified upsetting process had a lower deformation load and effective stress compared to the conventional upsetting process. However, the effective strain values were relatively similar for both cases. The effective stress and strain distribution were inhomogeneous, which was attributed to the changes in the deformation temperature. For sustainable industrial processes where energy consumption and production rates are significant, the modified upsetting process was recommended.